Weft pile carpet



May 17, 1932. L. KOCH wmf'r PILE CARPET Filed 001:. 7. 1930 for zeonharcz %c71 Patented May 17, 1932 UNITED STATES LEONHARD KOCH, F OEj- JSNITZ IN VOGTLAND, GERMANY.

WEFT me CARPET Application filed October 7, 1930, Serial No.

This invention relates to the production of a novel chenille stock for use in the manufactureof weft pile carpets, and to the manufacture from such chenille stock of an improved weft pile carpet without a woven backing. It is a primary object of the present invention to produce a weft pile carpet Without a woven backing, while obtaining softness and depth of plush, softness or pli- 1 ability of the carpet fabric as a whole, a clearcut surface effect in the design, and the appearance of a connecteddesign on the back to such a high degree as to approximate to the properties of valuable oriental carpets.

Previous'attempts to make Axminster carpets without a woven backing have generally been limited to the use of a twine warp to permit the loops of the tufted pile to appear at the back of the carpet. The tufts of the chenille were in such case however too firmly bound around the stuiiing warp and the twine -Warp was too clearly visible. The appearance of the design on the back'of the carpet therefore lacked good continuity. Moreover the, very regular structure of the chenille "spoilt the clear-cuteffectof the design on the surface by producing stripes, that is to say, it was possible to distinguish one chenille shot from'anoth-er. The softness and depth of the plush and the softness or pliability of the carpet fabric as a whole were also spoilt by the difference in the warps employed. A strong taut thread, i. e. a stretched thread in the finished fabric was worked in together with two weaker threads so'that the latter bound the chenille shots below, but bound the majority of the stifiening shots above the taut thread. These stiffening shots which were above the taut thread and which conse- 40 quently lay over the chenille stuffing warp, in conjunction with the strong taut threads, made the carpet fabric stiff and shortened thefree length of the tufts, because they pressed the tufts against one another again above the stuffing warps. The softness and depth of the plush was thus detrinientally affected. It has also been proposed to interweave the chenille solely with a double twine ground warp which binds the stiffening shots in pairs 486,896, and. in Germany October 30, 1929. A

with a plain one and one weave. The stiffness of the carpet is howeverreduced by this method and it does not carry any other advantages with it, owing to the chenille being too firm and of too uniform a structure.

The present invention consists in the pro duction of a novel chenille stock, and in interweaving it in a novel manner with a double ground warp, insuch a manner that the two cooperate together to fulfil the object of the present invention. According to the present invention the chenille stock is produced by drawing the pile Weft freely around a plurality of stuffing warp threads alternately to right and left by the use of a single crossed warp between the stuiiing warp and binding warps on both sides of the stuffing warp. The chenille stock so produced is bound as weft in alternation with stiffening shots solely by the use, of a double ground warp which passes alternately over the binding warps and under the stuffing warp of the chenille, the double ground warp binding the stiffening shots in pairs with a plainone and one weave.

An example of the manner in which the invention can be carried out is illustrated in the accompanying drawings Whereon:-

Fig. 1 is a plan View of the chenille weave and Figs. 2 and 3 are sectional views of the chenille stock, assumed to be out between two neighbouring tufts.

Fig. 4. is a plan view showing the carpet weave and Figs. 5 and 6 are cross-sectional views in the direction of the carpet warp an chenille weft respectively.

As illustrated in Fig. 1, the pile wefts 1 of the chenille stock are in themselves quite loose from the three stuiiing warps 2 and are merely drawn around the stuffing warps by a crossed warp thread 3, which alternat-ely engages the right and left hand portions of successive pile shots. At distances m and y from the crossed warp 3, the

pile shots are bound to crossed warp'thread 6, at both sides of the stuffing warp, by the usual twine'binding warp 4 and 5. As the crossed warp 3 always passes around first one limb of a tuft and then the other limb of the next tuft, thelimbs .of the themselves "and consisting of fine threads,

takera bend inwardszat one side.

tufts which are not caught by the crossed warp 3, must be drawn with it by the aid of the twine binding warps 4, 5 and 6 at the same side of the stuffing warps as the free limb of the tuft. The tuft limbs directly caught by the crossed thread 3 are therefore unable to freely follow it. On the contray the twine binding warps 4,5 and 6 act as a resistance to it created by the resistance of the neighbouring tuft limb. Those tuft limbs which are drawn inwards directly over the *stutiing warp by the crossed warp 3 will therefore, at their free ends, bend outwards slightly about the twine binding warps and above the crossed warp 3 as a resistance and fulcrum. The neighbouring tuft limbs-drawn inwards .onlyat a single point by thetwine binding warps can .freely followthis pull and there- This is shown in a somewhatexaggerated manner in :FigsQ and 3. In Fig.2 the right limb -of'the1tuftis directly caught by the crossed warp 3 and its free end is bent outwards above the I-twine binding warps. The left limb caught only bythe twinebinding warps is only drawn inwards and therefore follows the same direction asthe rightlimb. In-Fig. 3 :the conditions are just the reverse; both .lim'bs'of the tuft :bend towardsithe left.

Thisc'henill'e stock thus exhibits adjacent :tuftllimbs directed alternately inwards and outwards. If such united chenille weft .shotsv are'pressed together when weaving the carpetgthe .tufts of one stock weft which are :bentin one direction can be caused to fit betweenithe oppositely bent tufts in the next 'L-StOCkWG ft, so 'that thetufts intermingle and the line of distinction between the shots is thus ef'faced andia-truestripeless surface effect is obtained in the design.

As shown in .Figs. 4,5 and '6 this chenille stock is now :bound in with two stiffening weft'threads '8 "by a double twine ground "warp 7, which passes alternately over the twineibinding warps 4, 5 and 6, see Figs. 5 and ,6, and under thestufling warps T2, the ground warp 7 binding the stiffening shots 'S-inpairs withaplain one and one weave. The ground warp'threads being similar in.

they cooperate in a'particularly advantageousmanner with the chenille stock. In the first place "this ground warp is fine enough :to pass through the loops of the tufts until it rests against the stuffing warps, and sec- 5ond'lyfthe loops of the tufts are loose enough to permit the ground warp to pass through it. The complete "absence of'any binding of the tuft loopsito the stuffing warp over the distance 1 of Fig. 1, and the fact thatthis distance .lies alternately to right and left, prevents thedesign formed on the back by the tuft loop-s from being too regularly in- :terrupted,iand also permits the formation of theituft loops to be looser, thereby permitting a more connected design to appear on the back of the carpet.

The fact that the twine ground warp passes over the binding warps l, 5 and 6 and under the stuffing warps of the chenille, acts to press them both together and thus brings them closer towards each other. This allows the tuft loops to hang downwards in a loose condition, the ground warp penetrates the tuft loops with more certainty, it becomes concealed withinthem, and makes the tuft loops softer. The pressure (if the twine ground warp against the binding warps of the chenille also strengthens the action of the crossed warp on the inclination of the tufts in alternately opposed directions. This ground warp therefore improves the clearcut surface effect of the carpet designonithe face.

As the twine ground warps are all of the same material, this causes thestiifeningshots to be bound in at about thesame levelzas the stuffing warp of the chenille. This is :also assisted by the three-stuffing warp threads, which lie entirely loose, because according to whether at anyplace alateral or a vertical pressure predominates, the stufling warp threads can lie'either closer above one another, as in Fig. 2, or somewhat nearer .together, as in Fig. 3, that is to say, they can themselves yield without forcingthestifiem ing shots to move upwards or downwards. The stiffening shots being positioned at the samelevel as the stuifingwarps ofthe chenille substantially improves the softness of the carpet, as well as the depth andsoftnesscof the plush, because this is not hemmedin above thestufiing warp by any stiffening shots.

I claim:

1. A weft pile carpet fabric comprising stock wefts cut from chenille made from pile wefts, sets of stufling warps, a crossed warp twined from side to side of each set ofstufiing warps with a pile weftinserted at everytwist, and binder threads unitingthepile wefts between the sets of stuffing warps,tstiifening wefts alternating with :thestock wefts, and ground warps interwoven "with the stock wefts and stiffenings wefts,.said stock wefts being assembled so that the'tufts of one stock weft which are bent in one directionfit between the tufts in the next stock Weft which are bent in theopposite direction.

warps, stiffening wefts alternating with-the stock wefts, and ground"warpsinterwoven With the stock wefts and stiffening wefts,

said stock wefts being assembled so that the tufts of one stock weft Which are bent in one direction fit between the tufts bent in the other direction in the next stock weft, said crossed warp being tensioned to pull the pile Wefts around the stuffing warps and force the ends of the pile wefts into staggered relation.

8. A weft pile carpet fabric comprising stiffening wefts arranged in pairs, a stock weft between each pair of stiffening wefts, said stock wefts exhibiting tufts bent alternately to right and left and cuts from chenille made from pile wefts, sets of stufiing warps, a crossed warp twined across each set of stuf fing warps with a pile weft inserted at each twist, and binder threads uniting the pile Wefts between the sets of stuffing warps, and ground warps interwoven with the stock Wefts and stiffening wefts, said ground warps passing over the binder threads of alternate stock wefts, under alternate pairs of stiffening wefts and under the stuffing warps of the intermediate stock wefts, and said ground warps being arranged in pairs one under and one over each stock weft and its adjacent pair of stiffening wefts, the stock wefts when assembled having the tufts of one stock weft bent in one direction and fitting between tufts in the next stock weft which are bent in an opposite direction.

Signed at Qelsnitz i. V. Saxony, Germany, this eighteenth day of September A. D. 1930.

LEONHARD KOCH. 

